Molded
body armor panels conformed to fit individual torsos based upon gender or, in custom applications, individual features of a particular male or female
torso. The individual body panels are constructed of multiple
layers of twill or other unconventional long float woven ballistic fibers with each layer impregnated with a curable
adhesive. Additional reinforcement may be supplied in appropriate areas, such as breasts, spine, sternum and edges. The multiple impregnated
layers of fabric are placed within a mold conforming to the particular
torso contour desired. The long floats of the fabric allows the
layers to stretch or compress as required to the particular shape desired. The
adhesive is cured in the mold under low heat and low pressure, binding the layers of fabric together, as well as binding the conformed yarns of each individual layer in permanent contour. Interior and exterior coverings for comfort and appearance may be supplied.